super freezer refurbishment guide - maersk · pdf filesuper freezer refurbishment guide ... it...

17 July 2013

Super Freezer Refurbishment Guide (Draft)

1.0.1 General and process chart 1.0.2 Basic requirements on spare parts storage 1.0.3 Visual inspection 1.0.4 Gas sample flame testing (R134a) 1.0.5 R134a system cleanup procedure 1.0.6 Function and operational Check: 1.0.7 Buffer tank modification 1.0.8 Unit cannibalization 1.0.9 Estimation and repairs 1.0.10 Unit reinstallation 1.0.11 Full PTI 1.0.12 Quality managements by shop

Super Freezer Refurbishment

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1.0.1 GENERAL

The purpose of this manual is to standardise the SuperFreezer Containers’

Refurbishment and reporting thereof.

Process chart

Gate in

Visual inspection

R134a Flame test

Lab GCMS test

Estimation

Repair

Cannibalize unit from box

Full PTI

RCD installation Y/N

Releasing

Unit installation onto new box

Buffer tank mod modification

Y/N

Function check New box production

Vacuum & cleaning

R40 great than 0.05% R134a less than 99%

R40 less than 0.05% R134a Great than 99%

Disposal

Above repair limit

Below repair limit

Parts cannibalization from disposed unit for further units’ repairs

Truck unit to MCIQ

Truck new container to depot/shop

Pass

Working in

MCIQ Working in depot/shop

Failed R40

Without R40

Quantity controlling by

MCI

Second flame test

Pass

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1.0.2 Basic requirements on spare parts storage

The shop will at least have following parts in storage before the refurbishment

programme starts along with a good inventory level during the refurbishment

process.

Item Part No: Part description Quantity Remark

1 66-8811 Moisture Indicator , CRR-40 10 SF kit

2 102-796 Compressor, R-23 Super Freezer 10 SF kit

3 506-431 TXV, R-23 Super Freezer 10 SF kit

4 41-4523 HP-Switch , 470 PSIG , R-23 10 SF kit

5 506-421 Filter Drier, R-23 20 SF kit

6 504-1529 Sensor for Deep freezer ONLY 20 SF kit

7 66-9877 Orifice for R-23 TXV 506-431 10 SF kit

8

Adapter Unitor R23 bottle - 1/4

3/8 flare (Refer to following

pictures) 5

Prepared

by shop

9 R-23/KG 9,1KG Bottle

2

bottles

From

Sinochemlt

10

Buffer mod pipes (3/8, 9.52mm,

1.2mm copper) (Refer to following

pictures) 50

Prepared

by shop

11 4x6mm2 Cable 3000 ft From HF

12 104-759 Condensor motors 10 SF using

13

17-

10812-01 CAP,SV VLV (PLAST) 30 PLASTIC

14 66-3015 VALVE CAP ON R23(BRASS) 10 BRASS

15 506-161 CAP-DISCHARGE VALVE, R134A 20

16 66-9873 ADAPTER-SERV-PRESS-HIGH 20

17

12-

01125-02 R23 GAUGE 20

From

Carrier

18 66-1916 VALVE-SUCTION-R23 10

19 66-3942 VALVE-DISCHARGE-R23 10

20 33-2805 GASKET-R23 COMPRESSOR 10

21 78-1167 CONDENSER FAN 10

Remarks

Adapter Unitor R23 bottle - 1/4 3/8 flare, it is used on R23 cylinder for the connection type

change to link with gauges.

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Buffer mod pipes - 3/8, 9,52mm(O.D), 1.2MM (W.T) copper pipe

Orifice for R23 TXV, P/N 66-9877, we shall select the new type from ThermoKing with flat

head (in the green bottle) into this refurbishment project.

New type

Old type

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The Circuit breaker to be changed to 7.5 A Fuse during the refurbishment then the

shop shall have following parts in storage at least in following level before the project.

More details of that Fuse modification you can refer to Example A) below.

Part description Part No: Remark Quantity

TERMINAL STOP CLIPFIX 35.. 41-3687 100

FUSE, TERMINAL BLOCK...... 41-5105 50

FUSE 7.5AMP 32VDC......... 44-9359 50

Parts listed in above are mostly used on R23 system side but these standard parts on

R134a side and consumable parts shall be purchased in a proper sourcing channel and

kept in a good inventory level during the refurbishment program, like following ones,

Part description Part No: Remark Quantity

TXV-R134A 66-9900 5

MOTOR-EVAPORATOR 104-691 10

CONDENSER COIL 67-1589 5

EVAPORATOR COIL 67-1591 5

VALVE-DISCHARGE-R134A 66-9377 5

VALVE-SUCTION-R134A 66-9149 5

EVAPORATOR FAN 508-165 5

BEARING W6203MSL From SKF 5

BEARING W6205MSL From SKF 5

VALVE-BALL 66-9125 5

COIL VALVE LIQ 41-2399 5

SWITCH-HPCO 41-3250 5

VALVE SERVICE Section (R134a) 66-9149 5

1.0.3 Visual inspection

Please use Appendix I of “Super Freezer refurbishment function inspection

form” (Part A) on to record following checking/inspection actions

New parts

Old Circuit breaker

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Before performing RUN TEST the heading of the report must be filled in.

Container ID Number. Prefix always to be included

Unit Serial Number. Read the serial number plate on the reefer unit in

order to identify type of unit and then follow the manual, which cover the particular

type of unit.

UNIT manufactured year. Read the month and year of unit manufactured from

unit serial plate.

RUN TEST Date. Actual date when this RUN Test performed.

Ambient temperature. In degree Celsius (C)

Visual checck

Perform visual check on the machinery to ensure all parts are there

Check unit for leakage and cleanliness.

Inspect the unit for refrigerant leaks (trace of oil, low refrigerant level, and low-

pressure indication on R23 gauges and if any leak point at R-23 receiver inlet-

outlet).

Inspect condenser coil for excessive dirt, clean if necessary.

Inspect the control box including the controller door (that it fits), key pad, main

relay board, display, relays and controller.

Open Evap motor access door to see if any gasket missed or damaged. Check these

three motors are there.

Cleaning only to be done with fresh water at a maximum pressure of 30 Psig or

pressurised air at maximum of 60 Psig.

Check fasteners.

Check that unit mounting bolts compressor suspension bolts and all brackets are in

place and tightened properly.

Check power cable and plug.

1. Visual check power cable and power plug for physical and electrical damages.

2. The section of the cable shall be 4G6.0mm2 from HF (Folsgaard) and length of

cable shall be at least 18 meters and 0 splice.

3. A new one shall be placed with total length of 20 meters connected all way to

CB1 (32 Ampere) in the control box if the unit has one of following,

- Wrong cable used which is not 4G6.0mm2 from HF

- Less than 5 m (16 ft) of the cable is left.

- One or more than 1 splice kits were placed on the cable.

4. The plug shall the brand of “Mennekes” with type of “2175A” or “2175B”.

Replaced with the one from MCI via consumable list where required, P/N 818559A.

5. Power plug must be without any electrical or corrosion damages to the phase

legs and with gasket/safety pin and locking ring intact.

1.0.4 Gas sample flame testing of R134a

Carry out the sample test of R134a system, please refer to Appendix II of “Guide

to Taking a Refrigerant Sample”.

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1.0.5 R134a system cleanup procedure

Those units which have failed the flame test but have passed the lab test for R40 or

with limited R40 (has less than 0.05% R40 in system), it is agreed repairs should

carry on in order to get the units back in to service as following steps.

NOTE: Gauges and hoses used for recharging system MUST be confirmed

clean via Halide flame testing a known clean sample of R134a before

using.

If the units that contain at least 90% 134a gas and are contaminated with 5%

or less 142b

1. Open the container doors, run unit for 30 minutes, and then full cooling mode

(close doors) for at least one hour (-30’C). Monitor compressor temperatures

and shut down if temps exceed normal operating temps.

2. Attach gauge set to low and high side connections and recover all refrigerant in

a labeled (chlorine various) recovery cylinder. After 3rd shutoff on recovery unit

vacuum switch, close connections and remove recovery machine and cylinder

(gas to be disposed in complying with all applicable regulations, laws,

ordinances and best industry practices in local).

3. Disconnect contaminated gauge set (labeled) and fit clean R134a gauge set

(labeled).

4. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold

service gauges from service ports of both section pipe and discharge pipe, then

evacuate N2 from drier inlet and outlet tube.

5. Install new filter drier.

6. Evacuate system using high and low side connectors and leave active for a

minimum 4 hours @ 30 inHg of vacuum.

7. Using virgin R134a refrigerant, certified and tested, scale in the charge as

indicated on unit ID plate.

8. Run the unit for minimum 2 hours in full cool (-25C).

9. Turn off unit and allow stand idle for one hour.

10. Perform flame halide test and advise results.

After that, the STS code of 8936 (with max 6.5 man hours and gas cost as

material cost) would be used into the work order via MERC+.

If the units that contain less than 90% 134a gas and/or more than 5% 142b

1. Open the container doors, run unit for 30 minutes, and then full cooling mode

(close doors) for at least one hour (-30’C). Monitor compressor temperatures

and shut down if temps exceed normal operating temps.

2. Attach gauge set to low and high side connections and using refrigerant

recovery machine, recover all gas into a labeled (chlorine various) recovery

cylinder. After a minimum of three (3) shutoffs on recovery cycling switch,

close connections and remove recovery machine and cylinder. Note: reclaimed

gas to be disposed in complying with all applicable regulations, laws, ordinances

and best industry practices in local.

3. Remove compressor drain plug and drain oil from sump, flush sump to remove

as much residue as feasible.

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4. Refresh system with POE per machine specification (Polyol Ester Based type, TK

P/N 203-433).

5. Disconnect contaminated gauge set (labeled chlorinated) and fit clean R134a

gauge set (labeled virgin 134a).

6. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold

service gauges from service ports of both section pipe and discharge pipe, then

evacuate N2 from drier inlet and outlet tube.

7. Install new filter drier.

8. Evacuate system using high and low side connectors and two vacuum pumps

and leave active until gauge reads 30 inHg of vacuum, minimum operation

should be 4 hours.

9. Using virgin R134a refrigerant, certified and tested, scale in the correct system

charge as indicated on the ID plate.

10. Run the unit for a minimum of 2 hours in full cool (-25C).

11. Turn off unit and allow standing idle for one hour.

12. Perform flame test and advise customer of results.

After that, the STS code of 8936 (with max 6.5 man hours and gas cost as

material cost) and other STS codes, such as 8933 for Compressor oil

adding, would be used in the work order via MERC+.

1.0.6 Function and operational Check:

Please use Appendix I of “Super Freezer refurbishment function inspection

form” (Part B) to guide and record following checking/inspections to

ensure fol

- There shall not be any loosing or crack or deformation on the fastener

components or structures.

- The painter and primer on the structures, such as copper pipes shall be in one

piece without any damage or loss or missing in accordance with industry

standard.

- Refrigeration system shall be in functional condition

- The wires and circuits shall be in functional condition and without corrosion or

loss or missing.

Turn unit on,

Set/select temperature to a set point that puts the unit in full cool/pull down mode.

Allow unit to start up and run for 15 minutes.

Checklist:

1. Ensure proper rotation of condenser and evaporator fans

2. Ensure R23 compressor suction and discharge pressures are correct

3. Unit is cooling - sensor showing temperature trend towards set point

4. Ensure controller is updated with correct Container number, configuration.

5. No abnormal noise

6. Perform a manual defrost - should unit temperature not be low enough for

defrost to start manually force the heater relay and check the current draw.

7. Check alarm list (and alarms in message) to ensure all alarms to be recorded

and clear

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8. Carry out a full datalog downloading from the unit and save them in a folder

with the current container ID.

Further inspections,

9. Inspection of the evap and cond motor, to ensure they are free and they are not

noisy or have adverse bearing wear. (Replace the bearing or motor where

required).

10. Ensure all wire harnesses are free from damage and secure. Reworks would

need to be carried out on those units with improper repairs.

11. Inspection of the front Evap service hatch, to ensure that it is serviceable, shuts

firmly and that the seals are in place and serviceable. Replace where required.

12. Make sure d/frost drainage tubes are clear and cleaned.

13. Ensure “cork” tape insulation is in place and secure. (Please refer to example T)

14. Check that the Evap coil heaters are fitted correctly to the Evap coil, and the

wiring is correctly secured.

15. All control sensors are correctly mounted.

16. Ensure the air baffle plate is in place and free from damage.

17. Check the all Switchs, Liq Coil, drier if they are free from damage or corrosion

18. All valve caps, are in place, replace where required. Install boot in switch

ON/OFF and CB. Install cap retrieve connector if it’s missed.

19. Check R23 gauges are in place and free from damage.

20. Inspect the condition of the R134a compressor terminal box and valve plate.

Replace with the new plastic box and stainless steel cover (old type terminal

box) where required. Check R134A valve plate and replaced with cylinder head

bolt, if the bolt is heavy rusty.

21. Check regulators are adjusted correctly. They have been unadjusted in the

majority of the cases and should been check again according procedure. At least

crankcase pressure regulator to keep R-23 compressor with constant pressure.

Operate in Cool for 10 minutes and calibrated gauge, the pressure in low side of R-

23 compressor should read from 40 psi to 45 psi.

22. If the R134a compressor was heavy rusty, a repainting with primer and coating

will be needed.

The function testing together with visual inspection would be estimated

into MERC+ by STS0950 under MODE44 (FUNCTION TEST FOR SF REFURB)

with 0.6 man hours and a material cost under MODE43.

Examples,

A) Circuit breaker to be changed to 7.5 A Fuse

New parts

Old Circuit breaker

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41-3276 to be changed to 41-3687, 41-5105, 44-9359

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B) CB

Before After Breaker modification

C) ELEC CIRCUIT

Before

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After

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D) Sensor Wire Reconnection

Before

If the wrong sensor wire

splicing found, we shall re-

splice it again by bushing

with hot melt adhesive

inside as follows.

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After

E) HEATER CONTACT

Before

But if we shall replace a new supply

sensor, the wire shall be connected

from the connect point insider

controller box.

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After

F) MRB

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If the MRB connect port has Copper oxide, please use following cleaner to clean it.

But please replace the connect port if corrosion.

G) R134A HP Switch

Before After

If there is any rotating or shake on

the bolt, the replacement is need.

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H) Relay

Before

After

I) Condensor motor and Coil

Before

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After

1140 RPM, Wrong motor

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J) EVAP ACCESS DOOR (Heater access plate)

Before

1750 RPM, P/N: 104-759 Correct motor

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Proper sealing and air tightness are very important for heater access panel, evaporator access panels. Ensure door lock and sealing of controller door panel are good. Repair if necessary.

After

K) EVAP FAN MOTOR

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crack on evaporator fan mounting

L) LIQ COIL

LSV (Liquid line Solenoid Valve) is frequent failure part. Ensure to check/replace new one if necessary.

Before

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After

M) R23 COMPRESSOR

Before

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After

N) R134a Compressor terminal box

Before

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After

O) R134A Compressor Gasket

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P) R134a DRIER

Before

After

Q) Evaporator Coil Section

Ensure no screws/metal parts left on evaporator coil. Surprisingly in some cases, one screw which was left behind had been knocking evaporator coil due to vibration, caused serious leak. Always check/ensure all screws /bolts/nuts are tightened, nothing left on evaporator section.

There are two different types of R134a

compressor gaskets, shops shall purchase both of them from TK on this project.

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R) R23 Gauge

Before

Found bolt drop down to evapopator

coil between the unit frame, will cause the evaporator coil broken.

If there are any cracks, pulverization or leakage, the R23 gauge shall be replaced.

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High pressure in R23 discharge pressure gauge most of the time. Thus, it is easy to get

leaks at small capillary tube. Ensure to check/repair/ replace new gauge and capillary

tubes to prevent leak.

After

The pipes shall be protected and fasted by both Heat Shrink and protect Tubes to avoid shake damage.

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S) R23 HP/LP SVC VALVE

Before

Both discharge and suction gauge on R23 system shall use P/N 12-01125-02 for 500 psig from Carrier.

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After

T) R134a LP Service valve

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Before after

U) Service cap

Before

After

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V) Tube

Before

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After

W) Power Cable and plugs

Before

These “cork” tape insulation shall

be supplied by shops.

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After

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The cable shall be 4G6.0mm2 from HF (Folsgaard), P/N.

The plugs shall be supplied by MCI via consumable parts lis, P/N 818559A.

X) USDA sensors

Before

After

These USDA sensors shall be supplied by MCI via consumable parts list, P/N

818556B (USDA Temperature Sensor, Ø6,0 PT100)

4G6mm2

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Y) Evaporator fan motor bearings

Special grease type such as “lithium-soap greases” has been used successfully at the temperatures of minus 60ºF (-51 deg C). However, the grease type used in evaporator fan motor may not be good enough for minus 60 deg C range. We experience frequent evaporator fan motor bearing failure, probably due to grease type which could not work well in very low temperature range for long run. Ensure to check/replace new evaporator fan motor/ball bearings

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Z) Grounded heaters , poor connection at heater cables

Poor insulation/grounded heaters are caused by improper wire connections. Check, replace new heaters (if necessary) and insulate connection wires properly.

1.0.7 Buffer tank modification

1. Removal and weighing back in of the R134a gas to ensure the correct charge.

(This action shall be carried out in above mentioned function inspection and

repair process)

2. Removal and weighing back in of the R23 gas to ensure the correct charge.

3. When R23 systems are empty, to perform a leak test with N2. (Nitrogen is under

15,170 kPa, 151.70 bar, 2200 psig pressure in a full cylinder at 21 C (70 F).

4. Replace R23 Filter driers. (The R23 unit is a sweat in type, P/N 506-421).

5. That R23 compound gauges are in place and are working.

6. Inspection of all pipework and paying attention to the known weak areas.

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Another weak point which could suffer further fracturing in the future, please

take inspection on that as well.

7. If the buffer tank modification was not carried out on the unit before, a rework

of loop into buffer tank shall be conducted to increase the diameter and number

of loops as follows.

- As part of the rework, change the angle of the pipe from the valve leading

into the loop to the buffer tank.

- Suggested angle is approx 30 degrees instead of 40-45 degrees to alleviate

stress, using 3/8, 9,52mm copper pipe.

- Have the new pipe brazed in to as a posed to on to the buffer tank.

- Straighter pipe entering the buffer tank as opposed to the current angle

- The dry nitrogen (N2) be used to purge the system during any solder

operations and also for the leakage checking after welding.

- Remark in the machinery side with words of “Buffer tank mod done” with

the date and location information.

8. A STS code 8219 can be used into MERC+ with 8 man hours and a

material cost of RMB3000. That material cost will include, a full charge

of R23 gas (worse case) leak testing, N2, R23 f/drier (P/N 506-421) in

fact everything to carry out the repair.

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- There is NOT be any further R23 gas cost or R23 f/drier accepted by other

STS codes in the same one unit if it requests the buffer tank modification.

- R23 F/drier (P/N 506-421)’s price (list price USD94.18, about RMB600) shall

be cut off from total material cost with the filter direr part number inputs.

- Each unit has 3.2 kg R23 inside and if the system need full R-23 adding once

leakage, then the material cost shall be 3000 - 600 = 2400 RMB

- If the system has full R23 without any leakage and you just recharge the gas

after recovery, then the material cost shall be input at 3000-600-1500 =

900 RMB to cover other material cost like system recovery/re-charge

actions, N2 using, etc.

Finishing

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1.0.8 Unit cannibalization

Remove the unit from the old box with proper equipments and a forklift. Suggest

referring to the manufacturer’s instructions for this risk assessment.

Unit cannibalization can also be carried out before buffer tank modification

checking. That will depend on the repair cost in above compared with repair limit

set in MERC+.

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1.0.9 Estimation and repairs

Submit estimation into MERC+ with current (old) container ID under MODE43 for

Maersk /MCI’s evaluation and then arrange repairs after approval. The repair action

would be conducted together with buffer tank mod modification.

MCI will conduct the evaluation on these to be disposed units to see if any old parts

would be removed from them for further repair using. Shop would use them with a

material cost at 1/5 of list price rather than the part number in MREC+ to cover

their additional action of parts removal and testing.

All these R134a used onto the unit shall be tested by flame halide tester of each

new cylinder. Each Gas usage records shall and filled into Gas Logbook. Please refer

to Appendix III of “R134a flame test guide” for more details on the cylinder

gas flame test.

Shop shall at least have 3 separate Freon recovery machine & cylinders for the gas

recovery and collection. All clean (good) R134a from the unit, which passed unit

samples flame test, would be re-used during repair works by one set of recovery

machine & cylinder. The second set is used for contaminated R134a. The last one

set shall be working for R23 recovery and re-using. Do not mix gases pulled from

different system or cleaning/contaminated units.

Mounting Bolts

Unit mounting bolts should be tightened to a torque value of 204 N.m (150 ft-lb).

Compressor and fan motor mounting bolts should be tightened to a torque value of

20 to 21 N.m (15 to 20 ft-lb).

Cleaning of machinery

After repairs, a cleaning of the machinery side should be carried out and remove all

old labels/stickers, oil smear and impurity. Cleaning only to be done with fresh

water at a maximum pressure of 30 Psig or pressurised air at maximum of 60 Psig.

Insulation

TK recommend the insulation value of compressor and fan motors and heaters to

ground is minimum 1M Ω or more when measure with Mega Ohm meter with 500V

output

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Before

After

1.0.10 Unit reinstallation

This action shall be done in MCIQ

1.0.11 Full PTI

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Check the unit and box ID to ensure they are in the same. Change the container

number in controller to align with box. The correct software (120608) is in installed

along with the correct Date, Time and Container ID.

Install RCD onto the unit if it was not fitted before. Remove the back up battery

together with wiring inside control box and mounting brackets during RCD installation.

Please refer to Appendix IV of “Maersk RCD Installation Guide Hand-out for

more details.

The normal full PTI process would be followed. Please refer to Appendix V of

“SuperFreezer PTI form”.

The estimation shall be submitted with new container ID into MERC+ for PTI and

RCD installation. STS8940 (FULL PTI FOR SF REFURB ) under MODE44 can be

used for that. Each work order shall be recorded with old container number in the

remark filed for further checking.

1.0.12 Quality managements by shop

Shop should have its own Quality controlling and management team to record and

check each step carried out in the refurbishment. Then the QA documents from the

depot/shop on their work shall be signed off by the person in charge finally.

super freezer refurbishment guide - maersk · pdf filesuper freezer refurbishment guide ... it...

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